Confidential

Troubleshooting Guide | Order Mover | 048483-1

Revision History ......................................................................................................................................3

1. General Information ...........................................................................................................................4

1.1 Useful documentation ..................................................................................................................4

1.2 Integration in the Skypod Syste m .................................................................................................4

1.3 Power supply.................................................................................................................................4

1.4 PLC – Astar communication ..........................................................................................................4

1.5 Motor cards...................................................................................................................................4

1.5.1 Structure ................................................................................................................................4

1.5.2 Status LED ..............................................................................................................................5

1.5.3 Power supply..........................................................................................................................9

1.6 Dry contacts ................................................................................................................................1 0

1.7 Bypass .........................................................................................................................................1 1

1.8 Configuration ..............................................................................................................................1 2

1.8.1 Maintenance Page ...............................................................................................................1 2

1.8.2 Project Builder......................................................................................................................1 3

2. Troubleshooting – where to start ? ..................................................................................................1 3

2.1 HMI, errors..................................................................................................................................1 3

2.2 How to know if the PLC is runnin g ..............................................................................................1 4

2.3 Common hardware issues...........................................................................................................1 5

2.3.1 Belts......................................................................................................................................1 5

2.3.2 Cell s ......................................................................................................................................1 6

2.4 PROFINET network exploration ..................................................................................................1 6

2.5 Good practices for handling error s .............................................................................................1 7

2.6 Analysing ASTAR logs ..................................................................................................................1 7

2.7 Checking Preparation Container status in database...................................................................1 7

3. Issues and resolution ........................................................................................................................1 8

3.1 Order Mover disconnected.........................................................................................................1 8

3.2 Barcode reader doesn’t scan the barcodes ................................................................................1 9

3.3 Preparation Containers do not come in the alveolus .................................................................2 0

3.4 A transfer table is not working....................................................................................................2 1

3.5 Preparation Containers do not go where they should, or tracking losses..................................2 2

3.6 Problem at system interface (Dry contacts issue) ......................................................................2 3

3.7 Preparation Containers are askew..............................................................................................2 3

Confidential | 2 of 27

Troubleshooting Guide | Order Mover | 048483-1

3.8 Collision between preparation containers..................................................................................2 3

3.9 Oversize does not work...............................................................................................................2 4

3.10 Bypass does not work ...............................................................................................................2 4

3.11 Put to light does not work ........................................................................................................2 5

3.12 Loads on the robot hit the Order Mover frame........................................................................2 5

3.13 Preparation Containers are blocked .........................................................................................2 5

3.13.1 On a Decision Point............................................................................................................2 5

3.13.2 At the interface with another OM or the external system ................................................2 6

3.13.3 At tackers (stoppers)..........................................................................................................2 6

3.13.4 Somewhere else.................................................................................................................2 7

Revision table

Revision

Date

Author

Modifications

1

Initial revision

Confidential | 3 of 27

Troubleshooting Guide | Order Mover | 048483-1

5595-A

5595-B

/

5595-C

5595-D

24911-A

/

5595-E

9299-A

9299-B

Electrical

Drawings

Technical

File

Automation

Manual

Localization

Spare Parts

Installation

procedure

An Order Mover uses the following interfaces to work with the rest of the Skypod System:

•

380V power distribution from the Skypod System power bus

Ethernet connection from the associated Picking Station (note: all Order Mover PLCs have the

same IP 10.0.0.20 and thus are on a different subnet than the rest of the Skypod System. The

Picking Station acts as a gateway to route the communication between Astar and the Order

Mover)

•

Dual-channel dry contacts to get the Skypod System safety information (note: the PLC only

receives the information, it’s not part of the safety ASI loop).

Dry contacts to interface with other Order Movers or an external system (Ready to Receive /

Ready to Send signals).

SEW cards are daisy-chained on a few branches that run along the frame :

•

One under the alveolus

One for the output buffer

One for the input buffer

One on each side of the fixed drain (+ variable drain if any)

The full structure can be found in the Technical File and Electrical Drawings available for each revision.

In case of failure of one particular SEW card, all cards plugged after that one in the chain can be seen

as disconnected even if they are healthy.

Confidential | 4 of 27

Troubleshooting Guide | Order Mover | 048483-1

So considering the example below, if cards A10-1-02, 03, 04 and 05 are seen as disconnected on the

Maintenance Page, the problem is likely coming from A10-1-05 or from the connection between A10-

1-05 and A10-1-07.

Disconnected

Check cards and

connections

Confidential | 5 of 27

Troubleshooting Guide | Order Mover | 048483-1

Confidential | 6 of 27

Troubleshooting Guide | Order Mover | 048483-1

Confidential | 7 of 27

Troubleshooting Guide | Order Mover | 048483-1

Confidential | 8 of 27

Troubleshooting Guide | Order Mover | 048483-1

SEW cards are powered by two ASI lines : the yellow one is the logic supply and is permanent, the

black one is the power supply and is cut when an emergency stop is triggered.

SEW can be either vampirized directly on ASI lines or be powered by a derivation module.

On derivation modules, four LEDs in total indicate the logic and power voltage presence. When the

safety is active, all four LEDs shall be lit, otherwise it indicates either a power supply fault or a broken

fuse.

Confidential | 9 of 27

Troubleshooting Guide | Order Mover | 048483-1

For the wiring and logic of dry contacts, refer to the part §6.3 and subsequent parts of the document

018642-2 Order Mover Integration Manual.

For dry contacts debugging, a “Dry Contacts Test Mode” is available on the Maintenance Page :

Confidential | 10 of 27

Troubleshooting Guide | Order Mover | 048483-1

For each interface, the status of Ready to Send and Ready to Receive signal are shown (a red arrow

for a False value and green arrow for a True value).

Signal logic on the Order Mover side :

•

Ready to Send is True when a load is present on the last conveyor step and no emergency stop

is applied on the system

•

Ready to Receive is True when the Ready to Send signal from the external system is True, the

first conveyor step is available (no detection on the cell), the motor is running and no

emergency stop is applied on the system

•

The Order Mover expects the Ready to Receive signal from the external system to switch to

False between two consecutive outbound loads (to prevent load collisions in the case of

signal latency)

Bypass is a mode where the Order Mover will automatically convey loads towards the next/previous

one, without requesting decisions from Astar and therefore without entering the Preparation

Alveolus.

When switching to Bypass mode, any loads already present in alveolus or input buffer will be sent

towards the left exit.

This mode is intended to keep using the next Order Movers in the line in case of :

•

Failure on the Picking Station that prevents any communication between Astar and the Order

Mover

Confidential | 11 of 27

Troubleshooting Guide | Order Mover | 048483-1

•

Hardware failure in the buffers or in the preparation alveolus that prevents using the current

Order Mover for preparation.

The Configuration panel can be accessed by clicking on the “Gear” icon on the left of the maintenance

page. The following parameters can be accessed, according to the Order Mover revision :

•

SCS is in mono-barcode configuration : check if this preparation line uses Preparation

Containers which have only one label on one large face.

•

IO conveyor is present : if this Order Mover has a Left or Right IO drain (parts

017814/017842/030037/030039) alone or in addition to a variable drain (parts

020139/030035)

•

Intermediate conveyor length : number of steps of the Variable Drain (excluding IO drain if

any : if there is an IO drain alone, leave this value to 0). Tip : count the number of motor rollers

on the variable part.

Intermediate conveyor position : self-explanatory :)

After any modification, a hard reboot of the Order Mover shall be performed.

How to determine the intermediate conveyor length :

Confidential | 12 of 27

Troubleshooting Guide | Order Mover | 048483-1

The simplest way is to count the number of roller motors on the variable drain part.

The Maintenance Page is accessible with a web browser at http://station-xxxx:8080/ or

http://skypicker-xxxx:8080/ where xxxx is the alphanumeric name of the Station or Skypicker.

Confidential | 13 of 27

Troubleshooting Guide | Order Mover | 048483-1

Various status light can indicate if the PLC is running or not.

First, make sure the switch is on RUN position:

Make sure all PWR LEDs are lit. If not, it may indicate:

•

a power supply problem (check all circuit breakers and CE1 power supply and its submodules).

Confidential | 14 of 27

Troubleshooting Guide | Order Mover | 048483-1

•

E1 to E7 cards may not be plugged correctly into the rail.

Then check the main status light, the green LED should be lit. If an orange or red LED is lit, it means

the PLC is in error.

Direct connection test :

Plug an Ethernet cable directly from the PLC to your computer.

Set your network parameters as:

IP : 10.0.0.x (x != 20)

Subnet mask : 255.255.255.0

Then open a terminal in Linux or WSL and type :

Both commands shall output a success message.

Belts are subject to wear, which may result in a lack of adherence and thus to uneven speed between

rollers.

Creaking noises during operation often indicate worn out belts.

When doing a visual inspection, those signs indicate worn out belts:

•

A matte and porous rubber aspect (when new, the rubber surface is bright)

The presence of rubber dust

Also, when turning a roller by hand while blocking the adjacent one, it should not be “too easy” to do

so, otherwise the belt has to be replaced.

Confidential | 15 of 27

Troubleshooting Guide | Order Mover | 048483-1

Cells are optical components and thus are sensitive to excessive dust or presence of foreign objects.

Also, improper mounting will reduce the cells detection performance.

Use Profinet V3.0.0.5 or above to draw a network map of the equipment inside the Order Mover (SEW

cards, scanners…).

Download link : Dropbox (EXOTEC ENT)\E - Maintain it\1 - Gestion\6 - Procédures\009033 - How to

configure SEW board\proneta_3_0_0_5.zip

Confidential | 16 of 27

Troubleshooting Guide | Order Mover | 048483-1

It is advised to connect on the A10_SW1 (under the Preparation Alveolus) so that the network map

shape will be consistent with the drawings in the Technical File.

In Control Tower, go to the Preparation Container view and filter on non-empty value for “NodeId”

field. Doing so will display all Preparation Containers and their known position in database :

Alternatively, this query can be executed in a SQL client :

Confidential | 17 of 27

Troubleshooting Guide | Order Mover | 048483-1

SELECT

pc.pk, pc.barcode,

COALESCE(st.name, ap.name) AS pename,

cn.type,

pc.lastdecisiondate

FROM preparationcontainer AS pc

LEFT JOIN conveyoredge AS ce

ON ce.pk = pc.conveyoredgefk

LEFT JOIN conveyornode AS cn

ON (cn.pk = pc.conveyornodefk OR cn.pk = ce.targetnodefk)

JOIN ordermover AS om ON om.pk = cn.ordermoverfk

JOIN skypodconveyingsystemorder AS ord ON ord.ordermoverfk = om.pk

LEFT JOIN station AS st

ON (st.pk = om.preparationelementfk AND om.preparationelementtype =

'STATION')

LEFT JOIN autopicker AS ap

ON (ap.pk = om.preparationelementfk AND om.preparationelementtype =

'AUTOPICKER')

WHERE

(pc.conveyoredgefk IS NOT NULL OR pc.conveyornodefk IS NOT NULL)

ORDER BY ord.index ASC, cn.type ASC, pc.lastdecisiondate DESC;

In case of discrepancy between Preparation Containers position in database and actual position on

conveyors, remove the containers from the conveyors and put them in quarantine using the Picking

Station HMI or the “Action” menu :

Possible cause : PLC not operational

Refer to the part How to know if the PLC is running

Possible cause : connection issue

What to check : the Ethernet cable between the Picking Station and the Order Mover shall be plugged,

the activity LED shall be blinking.

Also, check that the Ethernet cable coming from the Order Mover Ethernet port goes directly to the

LAN2 port of the Picking Station computer.

Resolution : set the cabling in accordance with the Picking Station electrical diagrams.

Possible cause : Picking Station computer misconfiguration

What to check : From the Skypod Maintenance network, the following commands shall output a

success message (with xxxx replaced by the actual station name) :

Resolution : request assistance in the #support_infra Slack channel

Confidential | 18 of 27

Troubleshooting Guide | Order Mover | 048483-1

Possible cause (during commissioning) : wrong Ethernet cabling

What to check : at interfaces between two Order Movers, only dry contacts shall be connected.

Otherwise it will create network collisions and PLC won’t boot or create plenty of “Device

Disconnected” errors.

Left Variable and/or

IO Drain

Right

Variable

and/or IO Drain

Resolution : Refer to the installation procedure and redo step-by-step the Cabling part.

Possible cause : barcode printing issue

What to check : use a barcode verifier to check if barcodes are at least of grade C. If not, reading rate

is not guaranteed.

Possible cause : scanners not correctly setup

What to check : refer to 019843 Order Mover Automation Description to check if the setup matches

the label position on Preparation Containers used of this line.

Possible cause : scanners swapped or wrong addressing

What to check : check on the scanner screen if the device name matches the name expected by the

PLC.

Confidential | 19 of 27

Troubleshooting Guide | Order Mover | 048483-1

Resolution : use PRONETA to setup proper device address (or physically swap the scanners).

Possible cause : connection issue

What to check : check on the Maintenance Page if there is any “Device Disconnected” error. Check on

the scanner if the “NET” status LED is on.

Resolution : check Ethernet connection and the switch status in COM cabinet

Possible cause : hardware failure

What to check : check on the Maintenance Page if there is any “Device in Fault” error. Check on the

scanner if the “STATUS” LED is red or powered off.

Resolution : replace the scanner. Don’t forget to assign a device name to the new part using PRONETA.

Possible cause : power supply fault

What to check : Scanners are supplied by a cable vampirized on the yellow ASI cable. If only the scanner

is not powered, the fault may be due to the cable or connectors. If several other equipment are

powered off in the same zone, check the status of TR2, TR3 power supplies and circuit breakers in the

A10 cabinet under the preparation alveolus.

Possible cause : in Semi-finished, no doable Preparation Request

What to check : In Semi-finished mode, Preparation Containers only come into alveolus when the

Picking Station or Skypicker is in Preparation Mode, a category is selected and there are doable

Preparation Requests in queue.

Check in the Preparation Request view of Control Tower that there are Requests with doable = True

status = ‘NOT_FINISHED’ and a corresponding Category.

Possible cause : activation switch

Confidential | 20 of 27

Troubleshooting Guide | Order Mover | 048483-1

What to check : if the activation switch is off, it will prevent all movements on the dispatch area. This

switch is also monitored on the Maintenance Page :

Resolution : set the Activation Switch to 1.

Possible cause : Preparation Containers already there for Astar

Refer to the part Checking Preparation Container status in database

Possible cause : inductive sensor issue

What to check : there are two inductive sensors on each transfer table (Cp10xxxRlx for the rollers

position and Cp10xxxBde for the belts position). Under the transfer table, check that the two M12

connectors are firmly connected. In a valid position, one of the two sensors should have its status LED

powered on.

In the maintenance page, click on the transfer table and check if the “Direction” value is either “x” or

“y”. In manual mode, it is possible to select a state as “Direction Manual” and check if the transfer

table behaves accordingly :

If the transfer table switches position over and over without staying in a stable position, the issue is

probably linked to the sensors or their cabling.

Resolution : If a hardware issue is detected, the up/down mechanical assembly should be replaced.

Possible cause : mechanical failure

What to check : in manual mode, try to switch the position as shown above. If the transfer table does

not react, the up/down mechanism may be stuck. Additionally, an error such as “Motor Fault” on the

Maintenance Page may indicate a hardware failure.

For motor cards powered by a derivation module , check that all LEDs are lit when the safety is active.

If not, it indicates that a fuse broke down, likely because of a motor overload due to a mechanical

issue.

Confidential | 21 of 27

Troubleshooting Guide | Order Mover | 048483-1

Resolution : The transfer table sub-assembly shall be replaced in case of mechanical issue.

Additionally, if the derivation module fuses broke down, the module has to be replaced.

Possible cause : SEW card issue

What to check : On the Maintenance Page, look for errors such as “Device in Fault – A10-x-xx” or

Device Disconnected – A10-x-xx”.

Possible cause : Bypass activated

What to check : if the Bypass is activated, loads will cross the Order Mover without requesting a

decision from Astar.

Resolution : set the Bypass switch to 0.

Possible cause : Non-detection on cells

What to check : check that all cells around transfer tables are correctly mounted and detecting loads.

Pay particular attention to those clipped on plastic holders (in yellow on the screenshot below).

Confidential | 22 of 27

Troubleshooting Guide | Order Mover | 048483-1

Possible cause : wrong configuration regarding intermediate drain size

What to check : refer to Maintenance Page

Resolution : set the correct configuration on the Maintenance Page. Do a hard reboot of the OM after

a configuration change.

Possible cause : cabling issue

What to check : execute the 034874-2 Inspection Electrical Cabinet – COM procedure to look for

cabling errors or continuity issue

Resolution : open a Quality ticket and follow their instructions

Possible cause : wrong sequence on Ready to Receive / Ready to Send signals

What to check : go to the dedicated section or Order Mover Integration Manual for detailed

description.

Possible cause : preparation containers out of specifications

What to check : refer to 027988-2 Order Mover Fulfillment Containers Specification to see if

preparation containers meet the specifications.

Resolution : discuss it with the Project Manager.

Possible cause : issue with conveyors alignment or flatness

What to check : refer to the Flatness & General checks of the installation procedure

Resolution : correct the mechanical installation

Possible cause : sideguards issue

What to check : if sideguards are not aligned properly, loads may be blocked

Resolution : correct the sideguards positions

Possible cause : worn-out belts

What to check : refer to the dedicated part

Resolution : replace worn-out belts

Possible cause : uneven speed between OM and external system

What to check : with a tachometer, check that speeds of both system at interface are equal.

Resolution : report the issue to the Project Manager

Possible cause : preparation containers are too dark to be correctly detected

What to check : 027988 Order Mover Fulfillment Containers Specification forbids dark totes because

detection on roller sensors is not reliable.

Confidential | 23 of 27

Troubleshooting Guide | Order Mover | 048483-1

To test if containers are detected, it can be placed above a cell and check if the cell is active on the

Maintenance Page. Also the cell shall remain active even if the container is lifted of a few centimeters

above the conveyor.

Possible cause : sensor malfunction

What to check : check that all sensors in the area are clean and functioning well (see Cells ).

Resolution : clean the cells and replace in case of malfunction

Possible cause : motor malfunction

What to check : on the Maintenance Page, switch to manual mode, make the motors turn in a given

direction and observe if they are actually moving. Look for any error related to motors or SEW cards

in the Errors tab.

Resolution : replace any defective motor or SEW card

Possible cause : light issue

What to check : on the Maintenance Page, try to switch the light state (Off/On/Blinking) to activate it

manually.

Resolution : replace the light if defective

Possible cause : presence sensor issue

What to check : place a container on the Oversize step and check on the Maintenance Page if the

crosswise sensor (C10142a) is active.

Resolution : replace the sensor if defective

Possible cause : Tim100 configuration

Possible cause : button malfunction

Possible cause : Tim100 configuration

Possible cause : Tim100 not plugged

Possible cause : switch malfunction

Confidential | 24 of 27

Troubleshooting Guide | Order Mover | 048483-1

Possible cause : hardware issue with lights or buttons

Possible cause : cabling issue

Possible cause : Order Movers not properly declared in the graph

Possible cause : scanning issue on Picking Station

Possible cause : something abnormal under the frame

What to check : look under the Order Mover to see if these is any object that hinders the robot

clearance (loose cable…).

Resolution : make sure all elements are properly fastened

Possible cause : incorrect ground clearance

What to check : measure that the conveying height on the SCS line matches the purchase order. Also

check that the conveying height is consistent with the Skypod Tote height (conveying height 920mm

for 220 and 320mm totes, 1050 for 420mm totes).

The issue may have different causes according to the spot where Preparation Containers are blocked.

It may be :

•

On a Decision Point

At the interface with another OM or the external system

At tackers (stoppers)

Somewhere else (straight conveyor block or transfer table)

Add picture

Possible cause : no connection between the Picking Station and the OM

Resolution :

Check the connection status on the Picking Station Screen, it should display “Order Mover OK”.

If it displays “Order Mover KO”, check the Ethernet connection between the back of the Order Mover

and the Order Mover slot of the Station, and between the back of the OM and the PLC.

Confidential | 25 of 27

Troubleshooting Guide | Order Mover | 048483-1

Possible cause : Order Mover not (correctly) defined in the Project Builder

Check in the Project Builder if the Order Mover is correctly associated with the preparation element

(Picking Station or Skypicker) and all their order in correct (consecutive numbers starting at 0).

Possible cause : incorrect endpoint

Resolution : check the endpoint in the Order Mover view of Control Tower. It shall be

opc.tcp://station-xxxx:4840/ (or left blank).

Possible cause : communication issue between Astar and the Order Mover.

Resolution : restarting Astar will likely solve the issue (hint : it is a good practice to set a Fast Stop

before proceeding).

Possible cause : hardware issue on the inductive position sensors.

What to check : under the stopper, check that the two M12 connectors Cp10xxxah (high end sensor)

and Cp10xxxab (low end sensor) are firmly connected. In a valid position, one of the two sensors

should have its status LED powered on.

In the maintenance page, click on the Stopper and check if the “Direction” value is either “Up” or

“Down”. In manual mode, it is possible to select a state as “Direction Manual” and check if the stopper

behaves accordingly :

Resolution : If a hardware issue is detected, the whole stopper assembly should be replaced.

Possible cause : mechanical or roller motor issue.

What to check : check if the stopper can move in manual mode as above.

Confidential | 26 of 27

Troubleshooting Guide | Order Mover | 048483-1

Resolution : If a hardware issue is detected, the whole stopper assembly should be replaced.

Possible cause : issue with associated SEW card

Resolution : refer to the dedicated part

Possible cause : ghost tote

What to check : on the Maintenance Page, check if totes are memorized by the PLC but sensors not

activated.

Insert screenshot

Resolution : perform a “CLEAR” on downstream conveyor steps.

Possible cause : roller motor or SEW cards issue

Possible cause : logic supply failure

What to check :

On the Maintenance Page, look for “Device disconnected” errors.

Check on the SEW cards if any indicator LEDs are lit.

Resolution :

Check that all circuit breakers are closed in the main electrical cabinet.

Check all connectors on the yellow ASI line are connected where they should be.

Check the power supply in the C11 cabinet for any fault.

Possible cause : power supply failure

What to check :

Switch to manual mode and check if roller motors on downstream conveyor steps can move. If several

adjacent steps cannot move, it may indicate a power supply failure.

Look for “Power supply out of range” errors on the Maintenance Page.

Resolution :

Check that all circuit breakers are closed in the main electrical cabinet.

Check that all 380V (black round) cables are connected where they should be.

Use the Technical File to identify which CAR cabinet is supplying the faulty zone.

Inspect this CAR cabinet (under the conveyor frame) and the black ASI wire coming from this cabinet.

Replace the power supply in the CAR cabinet if faulty. Replace the black ASI wire if damaged.

Possible cause : detection cells problem

What to check : on the Maintenance Page, check if cells are activated or in error without any tote

present, or if any cell is not activated while there is a tote present.

Check if cells are clean and well aligned (for cells on clip holders). Add screenshot

Check the cells status feedback on the maintenance page when placing your hand above.

Resolution : replace a cell which does not behave properly.

Confidential | 27 of 27